Bernard TG017 Operations Manual

TECHNICAL GUIDE

For T-Gun™ Semi-Automatic

Air-Cooled MIG Guns –

200 amp Euro

300 amp Euro

350 amp Euro

 SAFETY & WARRANTY

INFORMATION

 INSTALLATION

 MAINTENANCE GUIDE

 TECHNICAL DATA

 OPTIONS

 EXPLODED VIEW & PARTS LIST

 TROUBLESHOOTING

 ORDERING INFORMATION

Please read instructions prior to use.

Save this manual for future reference.

2

TABLE OF CONTENTS

WARRANTY ........................................................................................................................................................................... 2

THANK YOU… ....................................................................................................................................................................... 3

GENERAL SAFETY ............................................................................................................................................................... 3

1.0 – INSTALLATION ............................................................................................................................................................ 4

1.1 INSTALLING T-GUN EURO TO FEEDER................................................................................................................... 4

1.2 INSTALLING NON-EURO POWER PIN TO T-GUN EURO – NEW STYLE ............................................................... 4

1.3 INSTALLING NON-EURO T-GUN MIG GUN TO FEEDER ........................................................................................ 4

2.0 – MAINTENANCE ............................................................................................................................................................ 5

2.1 TREGASKISS™ NOZZLE AND TOUGH LOCK™ CONSUMABLES ......................................................................... 5

2.2 LINER REPLACEMENT .............................................................................................................................................. 6

2.3 SWITCH REPLACEMENT ........................................................................................................................................... 7

2.4 NECK REPLACEMENT ............................................................................................................................................... 7

2.5 UNICABLE REPLACEMENT ....................................................................................................................................... 8

3.0 – TECHNICAL DATA ..................................................................................................................................................... 10

3.1 NECK DIMENSIONS ................................................................................................................................................. 10

3.2 GUN AMPERAGE RATINGS ..................................................................................................................................... 10

4.0 – OPTIONS ..................................................................................................................................................................... 11

4.1 DIRECT PLUG-INS .................................................................................................................................................... 11

4.2 SPECIALTY AND OPTIONAL ITEMS ....................................................................................................................... 11

4.3 FEEDER ADAPTORS ................................................................................................................................................ 11

4.4 CONNECTOR OPTIONS ........................................................................................................................................... 12

4.5 CONTROL PLUGS .................................................................................................................................................... 12

5.0 – TROUBLESHOOTING ................................................................................................................................................ 12

6.0 – DAILY WELDING GUN INSPECTION ........................................................................................................................ 13

7.0 – DECLARATION OF CONFORMITY ........................................................................................................................... 13

8.0 – EXPLODED VIEW AND PARTS LIST ........................................................................................................................ 14

9.0 – ORDERING INFORMATION ....................................................................................................................................... 16

9.1 GUN STANDARDS CHART ...................................................................................................................................... 16

WARRANTY

Product is warranted to be free from defects in material and workmanship for the period specified below after the sale by

an authorized Buyer. Should there be a defect please refer to our Return Merchandise Policy.

PRODUCT

WARRANTY PERIOD

T-Gun™ MIG Guns and Components

180 days

TGX™ Chassis and TGX Ready To Weld MIG Guns

90 days

Bernard reserves the right to repair, replace or refund the purchase price of non-conforming product. Product found not

defective will be returned to the Buyer after notification by Customer Service.

Bernard makes no other warranty of any kind, expressed or implied, including, but not limited to the warranties of

merchantability or fitness for any purpose. Bernard shall not be liable under any circumstances to Buyer, or to any person

who shall purchase from Buyer, for damages of any kind, including, but not limited to any, direct, indirect incidental or

consequential damages or loss of production or loss of profits resulting from any cause whatsoever, including, but not

limited to, any delay, act, error or omission of Bernard.

Genuine Bernard and Tregaskiss parts must be used for safety and performance reasons or the warranty becomes invalid.

Warranty shall not apply if accident, abuse, or misuse damages a product, or if a product is modified in any way except by

authorized Bernard personnel.

3

THANK YOU…

…for selecting a Bernard T-Gun

MIG Gun. The T-Gun MIG Gun is made from durable materials and components

engineered to perform in a rugged, welding environment. Your T-Gun MIG Gun is completely assembled and ready to

weld, and has undergone numerous quality checks to ensure high performance.

The instructions and illustrations in this technical guide make it easy for you to maintain your T-Gun MIG Gun. Please

read, understand, and follow all safety procedures. Keep this Technical Guide booklet as a handy reference when

ordering complete guns, parts and special options.

For customer support and special applications, please call the Bernard Customer Service Department at +1-708-

946-2281 or fax +1-708-946-6726 (International) or call toll free (USA and Canada) at 1-800-946-2281. Our trained

Customer Service Team is available between 8:00 a.m. and 4:30 p.m. CST, and will answer your product application or

repair questions.

Bernard employees are always striving to improve our products and services, and would appreciate receiving your

suggestions or comments. Please contact us immediately if you experience any safety or operating problems.

GENERAL SAFETY

Before installation or operation of T-Gun MIG Guns, please read the safety precautions listed below.

1. Always wear a properly fitted welding helmet with the proper grade of filter plate and suitable welding gloves.

2. All exposed skin should be covered with flame resistant, protective clothing. DO NOT WEAR CLOTHING

MADE FROM FLAMMABLE SYNTHETIC FIBERS.

3. Protective screens or barriers should be used to protect others from spatter, flash and glare while welding.

4. Prevent fires by ensuring that hot slag or sparks do not contact combustible solids, liquids or gases.

5. Ensure that operator’s head is not too close to the arc and that adequate ventilation is available.

6. Constant repetitive motion may lead to cumulative trauma disorders.

7. Do not touch live electrical parts. The following should be checked to prevent electrical shock:

 Equipment is adequate for the job, properly grounded and installed according to code.

 Faulty or damaged equipment is repaired or replaced.

 Proper operator maintenance is performed to prevent excess spatter accumulation in the nozzle, on

the contact tip or other areas of the gun.

 Electrical insulating components are in place and not damaged. Repair or replace if necessary.

 Operator and his/her surroundings are not wet.

 Cables are not wrapped around operator’s body.

 Equipment is off when not in use.

8. CSA Standard W117.2 CODE FOR SAFETY IN WELDING AND CUTTING obtainable from the Canadian

Standards Association, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3.

9. ANSI Standard Z49.1 CODE FOR SAFETY IN WELDING AND CUTTING obtainable from the American

National Standards Institute, 1430 Broadway, New York, NY 10018.

CALIFORNIA PROPOSITION 65 WARNING

This product, when used for welding or cutting, produces fumes or gases which contain chemicals known to the State of

California to cause birth defects and, in some cases, cancer.

This product contains chemicals, including lead, known to the State of California to cause cancer, and birth defects or

other reproductive harm. Wash hands after use.

(California Health & Safety Code Section 25249.5 at seq.)

4

1.0 – INSTALLATION

1.1 INSTALLING T-GUN EURO TO FEEDER

STEP #1

 Insert Euro gun to feeder.

 Thread Euro hand nut clockwise to tighten.

 Pull handle trigger, to feed.

1.2 INSTALLING NON-EURO POWER PIN TO T-GUN EURO – NEW STYLE

 Remove all Euro components, cut cable to remove old spring.

 Add new handle and spring.

 Add compression fit connection system (See Section 2.5 UNICABLE REPLACEMENT).

 Fully thread jam nut onto power pin.

 Thread power pin, with jam nut, into the rear connector cone.

 Torque the power pin connection by using two 19 mm wrenches, one on connector cone and one on the jam nut –

tighten to 24 Nm.

 Tighten jam nut.

 Reposition handle halves, reinstall handle lock nuts and tighten Philips screw.

 Install liner (See Section 2.2 LINER REPLACEMENT).

 Install gun to feeder (See below).

1.3 INSTALLING NON-EURO T-GUN MIG GUN TO FEEDER

Miller®, Lincoln®, Hobart®, Tweco® #4 and #5 Style

Power Pin

 Insert & secure non-Euro T-Gun MIG Gun into feeder

receptacle.

 Connect gun control plug to feeder.

 Pull trigger to feed wire through torch

NOTE: It is necessary to connect gas hose to barbed fitting on

Lincoln style power pin.

 Bernard Style and ESAB® Style Euro-Connector

 Insert gun into feeder

 Thread hand nut clockwise to tighten

 Pull trigger to feed wire through torch.

HANDLE

JAM

NUT

HANDLE LOCK NUT

POWER PIN

5

2.0 – MAINTENANCE

2.1 TREGASKISS™ NOZZLE AND TOUGH LOCK™ CONSUMABLES

IMPORTANT:

 Neck insulator MUST be in place before welding to properly insulate neck armor.

 Check all parts to ensure that connections are tight before welding.

 The retaining head MUST be tightened with a 5/8” (16 mm) wrench to prevent the contact tip from overheating

 DO NOT use pliers to remove or tighten the retaining head or scoring may result.

Removal and Replacement

Nozzle

 Pull slip-on nozzles off with a twisting motion.

 When installing the nozzle, ensure that it is fully seated.

Contact Tip

 Thread the contact tip into the retaining head.

 Torque to 30 in.-lbs. (3.5 Nm).

 The Tregaskiss Tip Tool (Part # 450-18 – for heavy-duty tips) or a pair of weld pliers are the optimal tools for

contact tip installation.

Retaining Head

 Thread retaining head onto neck with a 5/8” (16 mm) wrench.

 Torque to 80 in.-lbs. (9 Nm).

 DO NOT use pliers to remove or tighten the heavy duty retaining head or scoring may result.

Neck Insulator

 The neck insulator is pressed onto the neck by hand.

Thread-On Nozzles (Optional) - 300 and 350 amp Euro Models

 Thread-on nozzles do not require nozzle retainer and cannot be used with retaining head.

 Thread-on nozzle requires a neck insulator.

 External neck thread should be cleaned with a 9/16” - 18 die when changing the nozzle.

150/200 amp

300/350 amp

STANDARD NOZZLE

VARIOUS LENGTHS

AVAILABLE

STANDARD DUTY

TREGASKISS

TOUGH LOCK

CONTACT TIP

STANDARD DUTY

TREGASKISS

TOUGH LOCK

RETAINING HEAD

STANDARD DUTY

TREGASKISS

TOUGH LOCK

CONTACT TIP

LIGHT DUTY

TREGASKISS

TOUGH LOCK

RETAINING HEAD

NECK

INSULATOR

HEAVY DUTY NOZZLE

VARIOUS LENGTHS

AVAILABLE

HEAVY DUTY

TREGASKISS

TOUGHLOCK

CONTACT TIP

HEAVY DUTY

TREGASKISS

TOUGH LOCK

RETAINING HEAD

NECK

INSULATOR

6

2.2 LINER REPLACEMENT

NOTE: With Miller style power pins, liner is held captive by a guide cap which must be removed and replaced when changing

liner.

STEP #1

NOTE: Ensure power supply is off and gun is removed from feeder before proceeding.

 Remove nozzle, tip and gas diffuser.

 If power pin uses a liner set screw, loosen the set screw using a 5/64” Allen wrench, turning counterclockwise.

 If power pin is thread-in liner type, using a 10 mm wrench, turn thread-in liner collet counterclockwise until liner is free

from the power pin.

 With gun straightened, remove liner.

STEP #2

 Feed replacement liner through gun using short strokes to avoid kinking, twist liner clockwise if necessary.

 If power pin uses a liner set screw:

- Seat liner retainer with o-ring to shoulder inside bore of power pin.

- Secure by tightening liner set screw clockwise. Do not over-tighten.

 Thread-in liners and power pins require:

- Using a 10 mm wrench, turn thread-in clockwise and tighten in power pin to 3.5 Nm.

STEP #3

 Load pressure on the liner from the front of the gun by

pushing liner into the gun and holding in place.

 Using liner gauge, trim conduit liner with 19 mm stick-

out.

 Remove any burr that may obstruct wire feed, especially

on flat wire type conduit liner.

 Replace nozzle, tip and gas diffuser onto neck.

LINER

GAUGE

19 mm

7

2.3 SWITCH REPLACEMENT

Remove:

 Twist handle lock nuts counterclockwise.

 Slide handle lock nuts away from handle.

 Remove screw (Phillips) from handle and separate handle halves.

 Remove switch from switch lead connectors with needle nose pliers.

Replace:

 Connect switch lead connectors firmly onto switch terminals with needle nose pliers.

 Place gun assembly into handle half positioning neck in desired position.

 Fit switch into switch nest on handle, switch leads must lie parallel.

 Reinstall second handle half.

 Reinstall handle lock nuts on handle.

 Insert screw and tighten.

2.4 NECK REPLACEMENT

STEP #1

 Place old gun neck in vise.

 Twist handle lock nuts counterclockwise and pull away from handle.

 Remove screw from handle.

 To remove switch, refer to Section 2.3 SWITCH REPLACEMENT above.

 Remove handle halves, exposing jam nut and front of unicable.

 Loosen jam nut using two19 mm wrenches and unthread neck.

 Remove from vise and unthread neck by hand.

SWITCH

SWITCH LEAD CONNECTORS

LEADS

SWITCH TERMINAL

NECK

UNICABLE

SWITCH

HANDLE

LOCK

NUT

JAM

NUT

8

2.5 UNICABLE REPLACEMENT

STEP #1

 Cut unicable to length.

 Install strain relief onto unicable, with locking nut.

 Cut outer casing 65 mm from end to ensure proper switch lead

length.

 With switch leads pulled aside, cut unicable strands 50 mm

from newly trimmed outer jacket edge, cut cleanly and evenly

with sharp cable cutters. Spread unicable strands exposing

inner tube, trim 7 mm from inner tube.

STEP #2

 Position the inner tube clamp on inner tube.

 Insert inner support tube.

 Position and clamp outer hose clamps.

 Clamp inner support hose.

 Assemble spring guard in proper position.

 Slightly squash outer jacket clamp ears.

 Assemble inner tube compression clip.

 Position cone nut and tighten until threads

are not visible.

STEP #2

 Install handle lock nuts on neck.

 Thread jam nut onto new neck.

 Thread neck into unicable (hand tighten)

to desired orientation.

 Place neck in vise and tighten unicable

and jam nut.

STEP #3

 Reposition switch and handle.

 Reinstall handle lock nuts.

 Reinstall screw.

UNICABLE

NECK

JAM NUT

HANDLE

LOCK NUT

HANDLE LOCK NUT

SWITCH

SWITCH LEAD CONNECTORS

CUT HERE

50 mm

7 mm

65 mm

SWITCH

LEAD

CONNECTORS

SUPPORT TUBE

INNER TUBE CLAMP

5 mm

9

STEP #3

 Tape power cable and spare lead.

 Trim and strip control leads.

 Assemble control lead connectors.

 Position handle.

STEP #4

 FINAL ASSEMBLY - Follow identical procedure on

rear of gun.

If assistance is required, please contact your authorized Bernard Distributor or the Customer Service Department

at Bernard at 1-800-946-2281 (USA and Canada) or +1-708-946-2281 (International).

UNICABLE REPAIR KIT

REPAIR TOOL KIT

PART #

DESCRIPTION

PART #

DESCRIPTION

200

amp

300

amp

350

amp

450

REPAIR TOOL KIT (COMPLETE)

213-7

253-7

313-9

UNICABLE CLAMP KIT (COMPLETE)

INDIVIDUAL TOOLS

INDIVIDUAL PARTS

450-1

CABLE CUTTER

158

208

XXX

CONNECTOR CONE

450-2

CLAMP PLIERS - FOR CRIMPING OF OUTER

JACKET AND INNER TUBE CLAMPS

158-2

208-2

XXX

JAM NUT

209

259

XXX

CONE NUT

450-3

CONNECTOR CRIMPING TOOL - FOR SWITCH

LEAD TERMINALS

213-1

253-1

313-3

OUTER JACKET CLAMPS (2)

450-4

5/16" NUT DRIVER - FOR REMOVAL OF SWITCH

HOUSING

656-1

413-5

INNER TUBE CLAMP

450-5

KNIFE - FOR TRIMMING OF OUTER JACKET

213-4

413-4

SUPPORT TUBE

450-6

5/64" ALLEN KEY - FOR LINER REMOVAL

412-1

SWITCH LEAD CONNECTORS (2)

450-7

1/8" ALLEN KEY - FOR BODY SET SCREWS

NOTE: 150 AMP IS NOT REPAIRABLE.

SPARE LEAD

OUTER JACKET CLAMP

SWITCH LEADS

SUPPORT TUBE

INNER TUBE CLAMP

OUTER JACKET CLAMP

10

3.0 – TECHNICAL DATA

3.1 NECK DIMENSIONS

.

NECK

B

C

D

E

ANGLE

mm

135-60

60°

112

78

51

50

155-60

60°

103

78

51

45

205-60

60°

112

97

51

48

3.2 GUN AMPERAGE RATINGS

MODEL

60% DUTY CYCLE

100% CO

2

80% Ar, 20% CO

2

150 amp EURO

150

130

200 amp EURO

200

150

300 amp EURO

300

250

350 amp EURO

350

300

NOTE: Ratings are based on tests that comply with IEC 60974-7 standards.

19 mm

(NOMINAL SIZE FOR ALL NECKS)

C

A

D RAD.

E

B

11

4.0 – OPTIONS

4.1 DIRECT PLUG-INS

PART #

DESCRIPTION

USE ON FEEDERS

214

TREGASKISS™ POWER PIN

TREGASKISS QUICK CONNECT BLOCK HOBART 2000 SERIES

FEEDERS, TWECO® #4 RECEPTACLE BODY PART # TAK-1

214-1

MILLER ® POWER PIN - FOR .035 - 1/16" WIRE

MILLERMATIC 200 & 250, S22 SERIES, HOBART IRONMAN 210.

214-2

LINCOLN POWER PIN

LINCOLN LN7, 8, 90 LN 25, NA2, A-10

214-12

TWECO® #5 STYLE & MILLER POWER PINS

TWECO #5 QUICK CONNECT BLOCK & HOBART FEEDERS

414-11-2

O-RING FOR MILLER ® POWER PINS

414-12-2

O-RING FOR TWECO® #5 STYLE & MILLER POWER PINS

RECEPTACLE BODY PART #6TAK-1

214-116

GUIDE CAP ONLY (NEW STYLE)

414-116

GUIDE CAP ONLY FOR 414-11-116 (OLD STYLE)

4.2 SPECIALTY AND OPTIONAL ITEMS

ITEM

PART #

DESCRIPTION

1

401-10-87

SPOT NOZZLE (BRASS)

2

401-21

FLUX CORE NOZZLE (GASLESS)

3

401-41-50

EXTENDED REACH NOZZLE 3.5" (88.9 mm)

4

401-42-50

HIGH ACCESS NOZZLE (BOTTLENECK)

4.3 FEEDER ADAPTORS

To be used with 417 Quick-Connect Block

PART #

USE ON FEEDERS

418-3

ESAB® (NON EURO STYLE) & HOBART BETA MIG

418-4

HOBART® 27

418-5

LINCOLN® LN4, LN5, LINDE SWM 31, 3A & 32A

418-6

LINCOLN LN7, 8 & 9, LN 25 SUITCASE, LN22

418-7

LINDE® SWM-23

418-8

LINDE 35SWM-23

418-9

MILLER® 10A, 30A (MILLERMATIC 35S FEEDER)

418-10

MILLER 52E,54E, S21, S22 SERIES & MILLERMATIC 200 &250, 60 SERIES

418-14

OTC DAIHEN®

418-21

GILLILAND®

418-26

LINCOLN NA2

418-27

PANASONIC®

418-28

TWECO® #4

418-29

TWECO #5

418-35

KOBELCO®

12

4.4 CONNECTOR OPTIONS

Euro Connector option - for European style feeders and feeder

adaptors for 300 amp T-Gun MIG Guns.

Bernard Style Connector Option - for Quick Connect feeder

adaptors for 300 amp T-Gun MIG Guns.

*If switching from a new style Euro, a unicable repair is necessary!

PART #

DESCRIPTION

PART #

DESCRIPTION

425

EURO CONNECTOR ASSEMBLY – NEW STYLE

426

BERNARD STYLE CONNECTOR ASSEMBLY

425-10

EURO CONNECTOR BODY – NEW STYLE

426-1

CONNECTOR BODY

425-2

HAND NUT – OLD STYLE

426-2

LOCKING COLLAR

425-11

HAND NUT – NEW STYLE

426-3

LOCK SPRING

425-7

HANDLE ASSY WITH SCREWS

426-4

CONNECTOR HOUSING

425-8

CONTROL PIN

426-5

CONROL PINS

425-9

O-RING

426-6

O-RINGS

425-5

MOUNTING SCREW

4.5 CONTROL PLUGS

(Complete with plug lead and female connectors)

PART#

DESCRIPTION

419-1

AIRCO®

419-2

HOBART

419-4

MILLER (52E, 54E)

419-5

WESTINGHOUSE®

419-6

LINCOLN (LN7, 8, 9 ), NA2

419-7

MILLER (10E, 30E) & LINDE (SWM-35)

419-8

DIPSTICK 160/200, HOBART HANDLER, LINCOLN SP-100

419-10

DUAL SCHEDULE MILLER

5.0 – TROUBLESHOOTING

PROBLEM

POSSIBLE CAUSE

Poor Wire Feed

 conduit inner clogged or kinked

 incorrect liner size or contact tip

 liner cut too short and not seating properly in gas diffuser

 drive rolls too tight resulting in scoring of welding wire

 welding wire dirty rusty or too much cast

Short Tip Life

 drive rolls too tight resulting in scoring of welding wire

 welding wire dirty, rusty or too much cast.

 uncoated wire being used, increasing usage

 wrong wire size

 gun being run beyond its amperage range.

Gun Overheating

 loose retaining screw on quick connect block

 insufficient gauge power cable and/or ground cable

 loose connector cones and/or cone nuts

 guns being run beyond its amperage

 electrical malfunction in power source

Switch Malfunctioning

 bad connection of leads to switch terminals

 spatter built up between lever and switch housing

 contacts dirty in switch

 broken or worn switch lead

Weld Porosity

 spatter built up in nozzle blocking gas

 leaks in gas hose or improper connection

 o-rings on power pin are cut or damaged

 inner tube loose from connector cone

 poor wire feed (see above)

 improper shielding gas or welding wire

 rusty or poor quality welding wire

 gas flow improperly set

13

6.0 – DAILY WELDING GUN INSPECTION

Taking just a few minutes a day to perform the following quick checks for your T-Gun MIG Welding Gun will help

decrease weld problems, making your job easier and safer. It will also minimize downtime for maintenance and

increase consumable life.

BEGINNING OF SHIFT

 Inspect the cable for deep cuts or nicks. If bare copper is visible, repair with electrical tape.

 Check the Power Cable from the power source to the wire feeder for loose connections. Tighten if necessary. A

loose connection can cause poor electrical contact which will result in overheated cables and the loss of electrical

output.

 Check for tight connection of welding gun to feeder adapter. Tighten if necessary.

 Check for tight connection of welding feeder adapter into wire feeder. Tighten if necessary.

 Inspect Nozzle. Clean weld spatter and inspect insulation in nozzle. If nozzle insulation is damaged - replace

nozzle.

 Inspect Neck insulator on neck. If damaged, replace.

 Tighten Nozzle Retaining Head/Gas Diffuser on neck.

 Check gas holes in gas diffuser and clean if necessary.

 Tighten Contact Tip.

WHEN CLEANING NOZZLE

 Inspect insulation in nozzle. If damaged, replace.

 Inspect and clean gas holes in diffuser.

 Tighten nozzle retainer/gas diffuser to neck.

 Tighten contact tip.

7.0 – DECLARATION OF CONFORMITY

Manufacturer’s Name: Bernard

Manufacturer’s Address: 449 W. Corning Rd.

Beecher, IL 60401

USA

The manufacturer hereby declares that the product

Product Name: T-Gun™ EURO MIG Air-Cooled Welding MIG Guns

Model Numbers: 150 AMP, 200 AMP, 300 AMP, 350 AMP, 400 AMP,

500 AMP, 600 AMP

Product Options: All conforms to the following standards or

Bernard TG017 Operations Manual

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